Method for Producing Triangular Elements Designed for the Manufacture of Structures and Resulting Triangular Elements

ABSTRACT

The invention concerns a method for producing structures, whereof the geometric shape can be broken down into triangles, and which provide without any further treatment the structure with integrated airtightness, the double airtight partition enabling a coolant to be circulated or a relative depression to be generated and hence a more efficient thermal insulation, and also facilitating mounting with above all no need for a particular work site or complex and expensive foundations even on broken terrain. The method consists in prefabricating by moulding followed by assembling single-unit triangular structures, whereof the inside of lateral parts ( 5 ) is hollow through use of profiled sections, whereof the tops ( 6 ) contain no joints as a result of a plastic coating. The tops ( 6 ) comprise defined arc-shaped indentations ( 7 ), whereof the outer surfaces on either side comprise grooves ( 8 ), whereof the inner surfaces include a shoulder ( 9 ) comprising a groove ( 10 ) on both its surfaces, whereof the sides can have an extra thickness ( 11 ) at a specific angle, which has on one of the sides at least three openings ( 12 ) corresponding to recesses provided in the profiled section. Said structures are prefabricated in series by coating with plastic material, in a mould, a metal profiled section. The method is particularly designed for producing domes, greenhouses and submarine bells.

This invention relates to a manufacturing process for executing plane,curvilinear, polyhedral and spherical structures which may be decomposedinto a finite number of triangles and more particularly:

1. geodesic domes (proceeding from truncated cone icosahedrons)2. chapel-shaped greenhouses

Implementation of geodesic domes is conventionally carried out through aseries of different chins depending on the frequency chosen and arelinked in their tops by knots. Such knots are various devices designedaccording to the manufacturing and securing methods chosen for thechins.

The execution of chapel-shaped greenhouses is also conventionallycarried out using a series of chins, groins, shafts.

The execution mode for geodesic domes and chapel-shaped greenhouses doesnot, however, offer-even by having the same known characteristics incombination of the state of the art, as described in the above mentionedpatents, i.e. without the adjunction of other processes-4characteristics sought simultaneously:

-   -   An integrate water-tightness for the structure;    -   The double water-tight partition allowing the circulation of a        heat conducting fluid or the creation of a relative vacuum and        therefore a more efficient thermal insulations;    -   An easiness during the fitting process with, to the extreme        extent, the absence of complicated and costly work yard and        foundations, even on an uneven land;    -   A series manufacture of a limited number of identical elements        which may serve in constructing final structures of various        dimensions.

The process according to the invention allows remedying to suchdisadvantages. In fact, it consists, according to a firstcharacteristic, in manufacturing on a series basis and then assembling afinite number of 2 or more types of triangular structures withrectangular, isosceles or equilateral form having the followingcharacteristics:

-   -   Monobloc triangular structure made of a section drowned in a        plastic material.    -   Having a thickness and an inner shouldering allowing a double        wall;    -   Having a groove allowing lodging water tightness seals;    -   Having certain angular faces allowing assembling in dihedron of        groups of triangles.    -   Showing at their tops such indentations which complement,        through a cylindrical piece embedded during the assembling        process, both the fixation of final structures to the ground and        the water-tight tackling of the covering surfaces of the        triangular structures.

According to particular execution modes:

-   -   The triangular shape may be achieved in a steel section cut and        welded according to a specific template. Such section in        rectangular tubes is positioned at definite distances 110        between the inner walls of a female mould. The walls may already        be pre-covered with polyester resin armed with glass fiber.        After closing the three parts of the mould, polyurethane foam is        injected. The use of the mould ensures the series manufacturing        of triangular structures perfectly identical, including the        angles necessary to assembling.    -   During the coating process for the inner walls of the mould        using polyester resin armed by glass fiber, parallel grooves may        be executed on the three outer faces into the triangle        thickness. Such grooves may serve to lodge at least a water        tightness seal. Water tightness is ensured by the fact that        during the assembling process, each triangular structure gives        and receives a water tightness seal of the adjacent triangular        structure. Each outer face of a triangular structure is then        served by at least two water tightness seals despite the even or        odd position within the assembling sequence. The outer and inner        sides from both sides of the sealing between two adjacent        triangular structures can accordingly be fully insulated.    -   During the coating process of the inner walls of the mould using        the polyester resin armed with glass fiber, an indentation at        the level of each top of a triangular structure may be executed.        Such indentations are in a circle arch so as to make a complete        cylindrical hollow when such monobloc structures are joined in        their tops. The housings of seals are successive within the        indentations. In each of such indentations, a groove may be        provided in the middle point of other indentations in order to        perfect the water tightness ability of the cylindrical piece        embedded in the hollow mentioned above during the assembling        process. This latter piece may from a particular knot device        serving to secure to the ground the whole final structure in        form of dome or chapel-shape, using such cables and/or steel        tubes such as seamarks. Such piece may also serve as support for        such levers serving to chuck the covered surfaces of the        triangular structures.    -   Each monobloc triangular structure may include, by reason of the        form of the section, a shouldering over the inner faces of its        thickness. On such shouldering, there may be executed during the        coating process for the inner walls of the mould by polyester        resin armed with glass fiber, such grooves serving to housing        water tightness seal. Onto such water tightness seals then        fitted from both sides of the shouldering, covering surfaces in        double well are chucked. Such surfaces which may be in glass        material, polycarbonates, Plexiglas or any other material, even        non hard material, such as a plastic film, may be kept chucked        against the water tightness seals using such hard metallic        frames, secured to said levers using adjustable tightening        screws.    -   There may be provided along the thickness of each side of the        triangular structure during the shaping process of the section,        tree hollowing-outs, as follows:    -   The central hollowing-out ensures communication of the confined        space present in the double wall of two adjacent triangular        structures. A heat-conducting fluid, such as water may then        circulate from one triangular structure to another and then        through the whole final structure in a direction which can be        induced by means of a pump. Thus, an excess of heat may be        diminished or, to the contrary, heat transmitted by the        envelope, and then made watertight, may be brought along, to the        hermetically closed space formed by the inner volume on the        dome-shaped or chapel-shaped final structure. Also, by air        aspiration, a relative vacuum within the thickness may be        created, thereby increasing the insulation of the structure's        inner space from the outer environment.    -   The other two hollowing-outs located from both sides of the        central hollowing-out may serve to introduce threaded, slightly        curved and/or straight rods depending on the dihedron being        present. Such rods can secure, using such nuts and wedges which        perfectly embed into the hollowing-outs the sides of two        adjacent structures.

The attached drawings illustrate the invention:

FIG. 1: represents the manufacturing mode of a variant of the triangularstructure in a mould appropriate to it.

FIG. 2: represents a perspective view of a variant of the triangularstructure then manufactured using said process.

FIG. 3: represents a cross-section of the assembly in a dihedron of twoadjacent structures of the same variant.

FIG. 4: represents a cross-section in dihedron of two structures intheir tops by means of a cylindrical piece, as well as the levers andthe rigid chucking frames of the covering surfaces.

FIG. 5: represents the assembling method of equilateral and isoscelestriangles in a final structure constructed in form of a truncated coneicosahedrons and the way of doubling its volume.

FIG. 6: represents the assembling method of equilateral and righttriangles in form of a hexagon in a final structure of a greenhouse andthe way of doubling its volume.

By reference to those drawings the best way of executing the processconsists in coating with polyester resin, armed with glass fiber, orwith other coating plastic material (1) the inner faces of a mould (2)so as to include all its inner matrix. Then, a section (3) previouslycut and welded in a template according to the type of triangle and theheight levels chosen is placed at the bottom of the mould. Such sectionis maintained at a definite distance from the mould walls using theedges provided in the mould walls and penetrating the section. Afterclosing the parts of the mould, polyurethane foam (4) is injected.

In the execution form according to FIG. 2, the triangular structureobtained after hardening of the polyester resin (1) and the polyurethanefoam (4) is:

-   -   A monobloc structure, the inner part of sides (5) of which is        empty due to the use of the section (3).    -   A structure, the tops (6) of which include no joints, due to the        plastic coating.

A structure, the tops of which show indentations (7) in form ofwell-defined circular arch.

-   -   On the face of each side of a given structure there are grooves        (8).    -   The shouldering formed on inner faces of each side of a        triangular structure includes a groove on both its faces (10).    -   A structure, either of its sides is in thickness (11) according        to a definite angle.    -   A structure which shows on each of its faces at least three        ports (12) corresponding to hollowing-outs designed into the        section (3).

In the execution according to FIG. 3, two triangular structures areassembled according to a definite angle and make a dihedron (13) whichcontributes during the assembling process of the whole triangularstructures to the construction of dome having the form of truncatedicosahedrons or of a chapel-shaped greenhouse. Both hollowing-outs (14)then formed, in the two structures, by a rectangular tube section arepositioned face-to-face so as to form a port (12) in the thickness ofthe polyester resin armed with glass fiber (1). A threaded and slightlycurved rod (15) is introduced during the assembling process through thetwo hollowing-outs and secures the structures by means of nuts andwedges (16), which tightly embed within the section (3). The seals (17)are placed during the assembling process so as between the sides of twoadjacent triangular structures; there exist already two parallel sealsboth which close around one of the two triangular structures.

In the execution form according to FIG. 4, the knot device at the top ofa set of triangular structures assembled, is a cylinder (18) which isembedded in the hollow formed by the indentations (7) joined together.Such cylinder closes hermetically at the two edges by two lids (19)which hug the dihedral angle (13). Such cylinder includes in its middlepoint a seal placed during the assembling process between two parallelseals carried by the triangular structures into a groove (20) which isprovided to it within the indentations of each triangular structure. Thetwo cylinder lids are crossed by a threaded rod (21) which contains inits outer part:

-   -   A device (22) on which securing-to-ground cables and/or tubes        are fixed;    -   Two levers (23), each of which makes a bissectrix on one of the        two covered surfaces. They come, each, through an adjustable        tightening screw (25) to chuck a rigid frame (26) complete with        three arms (27) which are joining in height of the barycentre of        the triangle formed by the covering surface. The rigid frames        chuck thereby the covering surfaces (24) against the seals (28)        provided on each side of the inner shouldering (9) of the        triangular structure.

In the execution form according to FIG. 5, the assembly of 6 equilateraltriangular structures according to a hexagon (29) and of 5 isoscelestriangular structures according to a pentagon (30) contributes tomanufacturing a final structure of a dome constructed in the form of atruncated icosahedrons. However, the assembly of (4) equilateraltriangular structures (31) to form a triangular structure with doubledimension allows to form a hexagon of double size; this can be achievedby handling the order and the angle modifying the thickness of one ofthe sides of the elementary triangular structures during the mouldingprocess. By this process, also applied to pentagon, we may achievedoubling the volume of the constructed dome.

In the execution form according to FIG. 6, the assembly of 6 equilateraltriangular structures in form of a hexagon (29) to which we add righttriangular structures (32), in order to transform the hexagon into asquare, will contribute to manufacturing a final structure of achapel-shaped greenhouse. However, the assembly of 2 squares into 1rectangle by handling the order and the angle modifying the thickness ofone side of the elementary triangular structures during the mouldingprocess will double the height of the final structure and allowconstructing a chapel-shaped greenhouse twice bigger in size.

According to the process variants non-illustrated:

-   -   Triangular structures elaborated during the moulding process        without dihedral angles may, when assembled, form perfectly        plane structures with double wall. They may then serve as walls        and other additive elements in construction of geodesic domes        and chapel-shaped greenhouses.    -   The mould may be constructed, with the aim of perfecting the        finishing process, so as to allow the moulding process by        injection under pressure or under vacuum.    -   The mould may be constructed so as to obtain curved inner faces.        This allows obtaining triangular structures showing a curvature        in space dimensions on the three sides. Such structures        contribute, when assembled, to obtaining an entirely spherical        form.

As non-limitative example, the process uses series monoblocpre-fabricated triangular structures which will have the shape ofequilateral, isosceles and right triangle. In the case of a triangularstructure having the shape of an equilateral triangle, the dimensionswill be of about 0.80 meter of side, 0.10×0.06 m of thickness and make adouble wall of 0.04 m of depth.

The process according to the invention is particularly designed tomanufacturing domes in series (proceeding from truncated icosahedrons),chapel-shaped greenhouses and submarine bells.

1) A product composed of a monobloc triangular structure obtainedthrough covering with a material having plastic properties during themanufacturing process (1) into a mould (2), a section (3). Afterhardening of the plastic material into a mould, such product shows thefollowing known characteristics in combination with the current state ofthe art: The inner space of sides (5) is empty. The tops (6) do notcontain joints due to the plastic coating Shows on each of its sides atleast three ports (12) corresponding to hollowing-outs designed withinthe section. However, the product is characterized by the fact that: Themonobloc triangular structure is armed with sections. The triangularstructure has tops (6) showing indentations (7) in a pre-definitecircular arch. On the outer face of each side (5) of a triangularstructure grooves are provided (8) where seals (17) are lodgedcontributing to water tightness of the product's final structure whenassembling. The shouldering (19) formed by the inner faces of each sideof a triangular structure includes a groove (10) on each of its twosides. In such grooves, seals (28) may be lodged, contributing to watertightness of the product's final structure when assembling. A triangularstructure, one or more sides of which may be in over thickness (11)according to a predefined angle. 2) A product according to claim 1,characterized by the fact that the knot device at the top of a set ofassembled triangular structures there is a cylinder (18) which embeds inthe hollow space formed by the indentations (7) gathered. Such cylindercloses up hermetically at both edges by lids (14) so as to hug thedihedral angle (13) and secures both sides: Two clamping devices (22) onwhich securing-to-ground cables and/or tubes are fixed. Many levers(23), each of which is making a bissextrix onto one of the two coveredsurfaces (24) of each triangular structure. Each lever comes to chuck,using an adjustable tightening screw (25), a rigid frame (26) equippedwith three arms (27) which join each other in height at the barycenterof the triangle formed by the covering surface. The rigid frames chuckthereby the covering surfaces (24) against the seals (28) provided oneach side of the inner shouldering (9) of the triangular structure. 3) Aproduct according to claim 1, characterized by the fact that: Ahollowing-out (14) at least causes to communicate the confined spacepresent in the double wall of two adjacent triangular structures. Aheat-conducting fluid, such as water, thereby circulates from onetriangular structure to another and then throughout the whole envelopethen formed after assembly, of a final structure. Also, we may, by airaspiration create a relative vacuum within the thickness of suchenvelope and increase the insulation. Other hollowing-outs (14) locatedon the sides of a triangular structure may serve to introduce threadedrods (15), slightly curved and/or straight according to the dihedronbeing present. Such rods may secure, by means of nuts and wedges (16)perfectly embedding within the hollowing-outs, the sides of two adjacenttriangular structures; 4) A product according to claim 1, characterizedby the fact that the surfaces covering such triangular structures may bein glass material, polycarbonates, Plexiglas or any other material evennon-rigid, such as a plastic film when its is fixed in advance to therigid metallic frame (26). 5) A product according to claim 1,characterized by the fact that two triangular structures are joined toeach other side to side according to: Nil or dihedral angles (13) whichcontribute during the assembling of the set of triangle structures tothe construction of the final structure according to the desiredgeometrical shape. An order which may double the volume of the finalstructure with the same type of basic triangular structures. 6) Aproduct according to claim 1, characterized by the fact that the plasticmaterial (1) may be a paste with as main component plaster or cement. 7)A product according to claim 1, characterized by the fact that the sidesof the triangular structure may each have a curvature which contributes,when assembled, to obtaining a perfectly spherical form. 8) Amanufacturing process for executing plane, curvilinear, polyhedral orspherical structures which may be decomposed into a finite number oftriangular elements. Such process presents the characteristic, known incombination with state of the art, to assemble, by screws and nuts,prefabricated mono-block triangular structures. Nevertheless, suchprocess is characterized as per claims 1, 2, 3 and 5 by the fact thatthe final structures offer without further processes: An integratedwater-tightness for the final structure; The double water-tight bulkheadallowing the flow of a heat conveying fluid or the creation of arelative vacuum and then a more efficient insulation for the finalstructure. An easiness when assembling due to the over-thickness whichmay be performed in one or more sides of the mono-bloc triangularstructures, A number of foundations consisting in single anchorage holesin the ground.